From Pixel to Real Part: Creating Infinity Light with Polycarbonate

The transformation of the mobility industry demands innovative concepts

Automotive design serves as a key differentiator for car brands more than ever before, with lighting playing a crucial role in conveying emotions to customers. Traditional development processes, which involve multiple physical prototypes, are no longer sustainable in terms of time and cost due to the vast number of design possibilities and shorter product development cycles in automotive industry. 

Covestro addresses this challenge with an innovative virtual prototyping approach, transforming how car applications are developed and manufactured using high-performance polycarbonate as a carrier for both car interior lighting and structural functions.

Digital Product Development

Our comprehensive digital product development process seamlessly integrates design, optical simulation, engineering simulation, and manufacturing through:

• Makrolon® Ai automotive material solutions optimized for high-quality optical functions, customizable to customer needs at our global Color
   Competence Centers
• A Digital Sampling Library enabling creative exploration of color and structure effects
• Digital product design and optimization utilizing advanced material data for optical simulation and rendering workflows powered by X-Rite's TAC technology
• Global Application Development support for engineering and processing requirements

Experience the 3D Light Demonstrator  

Our 3D Light Demonstrator showcases the possibilities of a fully digital product development process: premium automotive interior design enhanced by innovative lighting functions, delivered through mass-production-ready processes – rapidly developed from initial concept to injection molding solution.

• Premium appearance delivered through high-purity Makrolon® Ai, offering customizable transparency from 0-90% and versatile color options
• Striking infinity lighting effects seamlessly integrated into automotive interiors through digital product design and optical simulation
• Switchable appearance alternating between black panel design and infinity, mirror tunnel lighting effects within a single component 
• Enabled by strong partnerships - Design by Miika Heikkinen by northernworks, Optical and Light Simulation by Eclat Digital Research SAS, technical texture design and tooling Laser engraving by pelplastic, and special metallized film from Nissha

Beyond material solutions: A Partnership Approach

Covestro delivers comprehensive support from digital concept to mass production for innovative automotive design solutions, backed by a strong network across the entire value chain:

• Global Color Competence Centers providing precise color matching
• Advanced material data integration throughout the digital product development process
• Extensive partner network of designers, lighting engineers, and mold makers, Texture and surface experts complemented by our in-house engineering and processing expertise

Visit us at K2025 to experience firsthand how our digital innovation and material solutions are transforming automotive interfaces - proving that the right combination of digital capabilities and materials creates effects that exceed traditional boundaries.